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Modeling of Materials Manufacturing Processes

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 February 2022) | Viewed by 34458

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Dr. Ismet Baran

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Guest Editor

Faculty of Engineering Technology, University of Twente, 7500AE Enschede, The Netherlands
Interests: fiber-reinforced polymer composites; numerical modeling; process simulations; pultrusion; material characterization

Special Issue Information

Dear Colleagues,

Understanding, describing, and predicting material behavior during manufacturing processes is key to optimizing the final product properties. This requires detailed analysis and characterization of the material and development of advanced material models utilized in process modeling and simulation. Generally, multiphysical phenomena simultaneously take places during manufacturing, such as heat transfer, fluid dynamics, solid mechanics, changes in material state and properties, phase transformations, changes in microstructure, internal stresses, and shape deformations. This makes the computational and numerical modeling of the manufacturing processing of materials very challenging.

This Special Issue therefore aims to publish new and novel research work focusing on computational process simulations and corresponding constitutive material modeling during manufacturing from atomistic to macroscopic length scales. All classes of materials and their characterization relevant to their manufacturing processes are covered in this Special Issue. Some examples of materials to be considered are fiber-reinforced polymer composites, polymers, metals, and ceramics. Theoretical as well as applied research papers relevant to computational modeling of materials and their structure–property relationships such as physical, mechanical, thermal, electrical, and optical during processing are welcome. Utilization of various numerical techniques in process simulations such as finite element, finite difference, finite volume, discrete element, meshless, and analytical methods together with experimental validation are within the interests of this Special Issue.

Dr. Ismet Baran
Guest Editor

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Keywords

numerical modeling
process simulations
material modeling
material characterization
manufacturing processes
heat transfer
solid mechanics
fluid dynamics
structure–property relationships

Published Papers (14 papers)

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Research

21 pages, 11474 KiB

Open AccessArticle

Determination of Heat Transfer Coefficient for Air-Atomized Water Spray Cooling and Its Application in Modeling of Thermomechanical Controlled Processing of Die Forgings

by Marcin Apostoł, Piotr Skubisz and Henryk Adrian

Materials 2022, 15(7), 2366; https://doi.org/10.3390/ma15072366 - 23 Mar 2022

Cited by 1 | Viewed by 1775

Abstract

The paper presents the method and results of determination of heat transfer coefficient for air-atomized water spray cooling with consideration of infrastructural factors of industrial cooling conveyor, such as effect of accelerated air. The established values of heat transfer coefficient were implemented into a numerical model of cooling line, with special definition of sprayers and the movement of the part subjected to quenching. After quantitative validation on selected samples, the obtained coefficients were used for the solution of the technological problem by means of localized cooling rate enhancement, which forms a case study confirming reliability of the established water spray heat transfer functions and suitability of the determined models for design of thermomechanical controlled processing of complex-geometry parts. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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18 pages, 5426 KiB

Open AccessArticle

An Extended Analytical Solution of the Non-Stationary Heat Conduction Problem in Multi-Track Thick-Walled Products during the Additive Manufacturing Process

by Dmitrii Mukin, Ekaterina Valdaytseva, Gleb Turichin and Artur Vildanov

Materials 2021, 14(23), 7291; https://doi.org/10.3390/ma14237291 - 28 Nov 2021

Cited by 3 | Viewed by 1945

Abstract

An analytical model has been developed for calculating three-dimensional transient temperature fields arising in the direct deposition process to study the thermal behavior of multi-track walls with various configurations. The model allows the calculation of all characteristics of the temperature fields (thermal cycles, cooling rates, temperature gradients) in the wall during the direct deposition process at any time. The solution of the non-stationary heat conduction equation for a moving heat source is used to determine the temperature field in the deposited wall, taking into account heat transfer to the environment. The method considers the size of the wall and the substrate, the change in power from layer to layer, the change in the cladding speed, the interpass dwell time (pause time), and the heat source trajectory. Experiments on the deposition of multi-track block samples are carried out, as a result of which the values of the temperatures are obtained at fixed points. The proposed model makes it possible to reproduce temperature fields at various values of the technological process parameters. It is confirmed by comparisons with experimental thermocouple data. The relative difference in the interlayer temperature does not exceed 15%. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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20 pages, 7752 KiB

Open AccessArticle

Numerical Modeling of Phase Transformations in Dual-Phase Steels Using Level Set and SSRVE Approaches

by Krzysztof Bzowski, Łukasz Rauch, Maciej Pietrzyk, Marcin Kwiecień and Krzysztof Muszka

Materials 2021, 14(18), 5363; https://doi.org/10.3390/ma14185363 - 17 Sep 2021

Cited by 2 | Viewed by 1559

Abstract

Development of a reliable model of phase transformations in steels presents significant challenges, not only metallurgical but also connected to numerical solutions and implementation. The model proposed in this paper is dedicated to austenitic transformation during heating and ferritic transformation during cooling. The goal was to find a solution which allows for the decreasing of computing time without noticeable decreasing the accuracy and reliability of the model. Proceedings to achieve this goal were twofold. Statistically Similar Representative Volume Element was used as a representation of the microstructure. It allowed for the reducing of the complexity of the computational domain. For the purpose of the model, carbon diffusion was assumed to be the main driving force for both transformations. A coupled finite element–level set method was used to describe growth of a new phase. The model was verified and validated by comparing the results with the experimental data. Numerical tests of the model were performed for the industrial intercritical annealing process. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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12 pages, 3126 KiB

Open AccessArticle

Analytical Solution of the Non-Stationary Heat Conduction Problem in Thin-Walled Products during the Additive Manufacturing Process

by Dmitrii Mukin, Ekaterina Valdaytseva and Gleb Turichin

Materials 2021, 14(14), 4049; https://doi.org/10.3390/ma14144049 - 20 Jul 2021

Cited by 6 | Viewed by 2276

Abstract

The work is devoted to the development of a model for calculating transient quasiperiodic temperature fields arising in the direct deposition process of thin walls with various configurations. The model allows calculating the temperature field, thermal cycles, temperature gradients, and the cooling rate in the wall during the direct deposition process at any time. The temperature field in the deposited wall is determined based on the analytical solution of the non-stationary heat conduction equation for a moving heat source, taking into account heat transfer to the environment. Heat accumulation and temperature change are calculated based on the superposition principle of transient temperature fields resulting from the heat source action at each pass. The proposed method for calculating temperature fields describes the heat-transfer process and heat accumulation in the wall with satisfactory accuracy. This was confirmed by comparisons with experimental thermocouple data. It takes into account the size of the wall and the substrate, the change in power from layer to layer, the pause time between passes, and the heat-source trajectory. In addition, this calculation method is easy to adapt to various additive manufacturing processes that use both laser and arc heat sources. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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19 pages, 11794 KiB

Open AccessArticle

Mesoscale Process Modeling of a Thick Pultruded Composite with Variability in Fiber Volume Fraction

by Onur Yuksel, Michael Sandberg, Jesper H. Hattel, Remko Akkerman and Ismet Baran

Materials 2021, 14(13), 3763; https://doi.org/10.3390/ma14133763 - 5 Jul 2021

Cited by 14 | Viewed by 3661

Abstract

Pultruded fiber-reinforced polymer composites are susceptible to microstructural nonuniformity such as variability in fiber volume fraction (

V_{f}

), which can have a profound effect on process-induced residual stress. Until now, this effect of non-uniform

V_{f}

distribution has been hardly addressed [...] Read more.

Pultruded fiber-reinforced polymer composites are susceptible to microstructural nonuniformity such as variability in fiber volume fraction (

V_{f}

), which can have a profound effect on process-induced residual stress. Until now, this effect of non-uniform

V_{f}

distribution has been hardly addressed in the process models. In the present study, we characterized the

V_{f}

distribution and accompanying nonuniformity in a unidirectional fiber-reinforced pultruded profile using optical light microscopy. The identified nonuniformity in

V_{f}

was subsequently implemented in a mesoscale thermal–chemical–mechanical process model, developed explicitly for the pultrusion process. In our process model, the constitutive material behavior was defined locally with respect to the corresponding fiber volume fraction value in different-sized representative volume elements. The effect of nonuniformity on the temperature and cure degree evolution, and residual stress was analyzed in depth. The results show that the nonuniformity in fiber volume fraction across the cross-section increased the absolute magnitude of the predicted residual stress, leading to a more scattered residual stress distribution. The observed

V_{f}

gradient promotes tensile residual stress at the core and compressive residual stress at the outer regions. Consequently, it is concluded that it is essential to take the effects of nonuniformity in fiber distribution into account for residual stress estimations, and the proposed numerical framework was found to be an efficient tool to study this aspect. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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23 pages, 3261 KiB

Open AccessArticle

Numerical Analysis of a Continuous Vulcanization Line to Enhance CH₄ Reduction in XLPE-Insulated Cables

by Mohd Fuad Anwari Che Ruslan, Dong Joon Youn, Roshan Aarons, Yabin Sun and Shuyu Sun

Materials 2021, 14(4), 1018; https://doi.org/10.3390/ma14041018 - 21 Feb 2021

Cited by 2 | Viewed by 1983

Abstract

Herein, we apply a computational diffusion model based on Fick’s law to study the manner in which a cable production line and its operating conditions can be enhanced to effectively reduce the CH

_{4}

concentration in cables insulated with cross-linked polyethylene (XLPE). Thus, [...] Read more.

Herein, we apply a computational diffusion model based on Fick’s law to study the manner in which a cable production line and its operating conditions can be enhanced to effectively reduce the CH

_{4}

concentration in cables insulated with cross-linked polyethylene (XLPE). Thus, we quantitatively analyze the effect of the conductor temperature, curing tube temperature distribution, transition zone length, and online relaxation on CH

_{4}

generation and transport during the production of 132 kV cables with an insulation thickness of 16.3 mm. Results show that the conductor temperature, which is initially controlled by a preheater, and the curing tube temperature distribution considerably affect the CH

_{4}

concentration in the cable because of their direct impact on the insulation temperature. The simulation results show 2.7% less CH

_{4}

remaining in the cable when the preheater is set at 160 °C compared with that when no preheater is used. To study the curing tube temperature distribution, we consider three distribution patterns across the curing tube: constant temperature and linear incremental and decremental temperature. The amount of CH

_{4}

remaining in the cable when the temperature was linearly increased from 300 to 400 °C was 1.6% and 3.7% lower than in the cases with a constant temperature at 350 °C and a linear temperature decrease from 400 to 300 °C, respectively. In addition, simulations demonstrate that the amount of CH

_{4}

removal from the cable can be increased up to 9.7% by applying an elongated and insulated transition zone, which extends the residence time for CH

_{4}

removal and decelerates the decrease in cable temperature. Finally, simulations show that the addition of the online relaxation section can reduce the CH

_{4}

concentration in the cable because the high cable temperature in this section facilitates CH

_{4}

removal up to 2.2%, and this effect becomes greater at low production speeds. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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17 pages, 5253 KiB

Open AccessFeature PaperArticle

A Numerical Analysis of Resin Flow in Woven Fabrics: Effect of Local Tow Curvature on Dual-Scale Permeability

by Hatim Alotaibi, Masoud Jabbari and Constantinos Soutis

Materials 2021, 14(2), 405; https://doi.org/10.3390/ma14020405 - 15 Jan 2021

Cited by 5 | Viewed by 2726

Abstract

Permeability is a crucial flow parameter in liquid composite moulding (LCM), which is required to predict fibre impregnation, void formation and resin back flow. This work investigates the dual-scale (micro- and meso-) nature of permeability during resin infusion into woven fabric by incorporating the intra tow flow where the degree of local tow curvature (tow/yarn undulation) is taken into account. The mesoscopic permeability of a dual-scale porous media in a unit cell is estimated using Darcy’s law, where the Gebart analytical model is applied for the intra tow flow in longitudinal and transverse directions with respect to distinct fibre packing arrangements. The results suggest that for a low fibre volume fraction (≤42%), the degree of local curvature at the mesoscale can be neglected. However, for a high fibre volume fraction (>42%) and a higher fibre bundle curvature, the proposed model should be adopted, since the resin flow is affected by a mesoscopic tow curvature that could result in around 14% error in predicting permeability. It is shown that the permeability results of the current study are in good agreement with and in the range of the retrieved available experimental data from the literature. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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17 pages, 3948 KiB

Open AccessArticle

Co-Bonded Hybrid Thermoplastic-Thermoset Composite Interphase: Process-Microstructure-Property Correlation

by Jamal Seyyed Monfared Zanjani and Ismet Baran

Materials 2021, 14(2), 291; https://doi.org/10.3390/ma14020291 - 8 Jan 2021

Cited by 12 | Viewed by 2677

Abstract

Co-bonding is an effective joining method for fiber-reinforced composites in which a prefabricated part bonds with a thermoset resin during the curing process. Manufacturing of co-bonded thermoset-thermoplastic hybrid composites is a challenging task due to the complexities of the interdiffusion of reactive thermoset resin and thermoplastic polymer at the interface between two plies. Herein, the interphase properties of co-bonded acrylonitrile butadiene styrene thermoplastic to unsaturated polyester thermoset are investigated for different processing conditions. The effect of processing temperature on the cure kinetics and interdiffusion kinetics are studied experimentally. The interphase thickness and microstructure are linked to the chemo-rheological properties of the materials. The interdiffusion mechanisms are explored and models are developed to predict the interphase thickness and microstructure for various process conditions. The temperature-dependent diffusivities were estimated by incorporating an inverse diffusion model. The mechanical response of interphases was analyzed by the Vickers microhardness test and was correlated to the processing condition and microstructure. It was observed that processing temperature has significant effect on the interdiffusion process and, consequently, on the interphase thickness, its microstructure and mechanical performance. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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15 pages, 7829 KiB

Open AccessArticle

Motion and Distribution of Floating Grain in Direct-Chill Casting of Aluminum Alloys: Experiments and Numerical Modeling

by Qipeng Dong, Yanbin Yin, Zhen Zhu and Hiromi Nagaumi

Materials 2020, 13(23), 5379; https://doi.org/10.3390/ma13235379 - 26 Nov 2020

Cited by 7 | Viewed by 1694

Abstract

Sedimentation of free-floating grains is the main origin of the negative centerline segregation in direct-chill casting of aluminum alloys. This study examines the motion and distribution of the floating grains during casting using experimental measurements and numerical modeling. The typical floating grains consisting of interior solute-lean coarse dendrites and periphery fine dendrites were experimentally observed only in the central region of the billet along with the negative segregation. The billet exhibits the strongest segregation at the center where the most floating grains are found. In simulations, under the action of the convection and the underlying forces, the grains floating in the transition region exhibit different motion behaviors, i.e., settling to the mushy zone, floating in the slurry zone, and moving upward to the liquid zone. However, most grains were transported to the central region of the billet and then were captured by the mushy zone and settled. Therefore, the floating grains comprise the largest share of the grain structure at the center of the billet, in agreement with the experimental results. Moreover, the simulation results indicate that the increased size of the grains promotes the sedimentation of the floating grains. These results are important for the future alleviation of negative centerline segregation in direct-chill casting of aluminum alloys. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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15 pages, 5135 KiB

Open AccessArticle

Modeling of Motion Characteristics and Performance Analysis of an Ultra-Precision Piezoelectric Inchworm Motor

by Bo Zhao, Ri Fang and Weijia Shi

Materials 2020, 13(18), 3976; https://doi.org/10.3390/ma13183976 - 8 Sep 2020

Cited by 5 | Viewed by 2180

Abstract

Ultra-precision piezoelectric inchworm motor (PIM) is widely used in the optical equipment, microelectronics semiconductor industry and precision manufacturing for motion and positioning, but the multi-physics field simulation model for estimating PIM performance and assisting motor design is rarely studied. The simulation model in this paper aimed to provide researchers with direct and convenient PIM performance evaluation to assist the motor design and development. According to the existing advanced inchworm motor products, a multi-physics field coupling model involving solid mechanics and electrostatics using the finite element method (FEM) was established. The motion gesture and performance (driving force and travel) of the PIM were analyzed, respectively. The simulation results showed that the motion gesture of the inchworm motor was well consistent with that of the actual motor product. The driving force from the simulation was close to that of the actual product, and the maximum error was 2.8%. As for the PIM travel, there was a maximum travel error of 0.6 μm between the simulation and official data. The performance parameters of the piezoelectric materials under certain specifications can be simulated by the multi-physics field coupling model. Therefore, the multi-physics field coupling simulation model is suitable for PIM performance evaluation and assisting motor development. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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16 pages, 7789 KiB

Open AccessArticle

Static Softening Behavior and Modified Kinetics of Al 2219 Alloy Based on a Double-Pass Hot Compression Test

by Lei Liu, Yunxin Wu, Hai Gong, Abdulrahaman Shuaibu Ahmad, Fang Dong and Huamin Yu

Materials 2020, 13(17), 3862; https://doi.org/10.3390/ma13173862 - 1 Sep 2020

Cited by 2 | Viewed by 1971

Abstract

In this paper, the static softening mechanism of a 2219 aluminum alloy was studied based on a double-pass isothermal compression test. For the experiment, different temperatures (623 K, 723 K, and 773 K), strain rates (0.1/s, 1/s, and 10/s), deformation ratios (20%, 30%, and 40%), and insulation periods (5 s, 30 s, and 60 s) were used. Based on the double-pass flow stress curves obtained from the experiment, the step rate expressed by the equivalent dynamic recrystallization fraction is dependent on the deformation parameters, which increases with the increase in strain rate and insulation time, while it decreases with the increase in temperature and strain. Based on the microstructure observed using electron backscattered diffraction (EBSD), the static softening mechanism of the Al 2219 alloy is mainly static recovery and incomplete static recrystallization. A new expression for the static recrystallization fraction is proposed using the reduction rate of the sub-grain boundary. The dependent rule on the deformation parameters is consistent with the step rate, but it is of physical significance. In addition, the modified static recrystallization kinetics established by the new SRX fraction method was proven to have a good modeling and prediction performance under given deformation conditions. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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18 pages, 6760 KiB

Open AccessArticle

Numerical Simulation and Experimental Confirmation of a Bimetallic Pipe Forming Process

by Zhiqiang Dong, Zhenzhen Xu, Wenke Wang, Zongyue Bi and Jianxun Zhang

Materials 2020, 13(16), 3561; https://doi.org/10.3390/ma13163561 - 12 Aug 2020

Cited by 8 | Viewed by 2407

Abstract

Most oil and gas is transported by pipeline, and corrosion causes a great threat to the service life of the pipeline; bimetallic pipe, which combines the advantages of good mechanical properties, good corrosion resistance, and relatively low price, is a good choice for high-pressure and corrosion-resistant pipe, but its manufacturing process and stress distribution are more complex than single metal pipe. JCO is a widely used cold forming method for pipes which is named by the shape of the plate in the forming process, i.e. J-shape, C-shape and O-shape, and the forming process is an important parameter that determines the level of imperfections and residual stresses in a pipe, and residual tensile stress will accelerate corrosion failure of the pipe. In this study, the three-dimensional (3D) finite element method (FEM) is used to simulate the pre-bending and JCO forming process of a 2205/X65 bimetallic pipe. The model and the simulated results are validated by digital image correlation (DIC) experimental and the opening width of the formed pipe billet, respectively. The influence factors of the stresses are studied. Further, a two-dimensional (2D) model is established to study the characteristics of bimetallic plate bending and the stress distribution at the interface of different materials, and the results are compared with that of three-dimensional model. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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19 pages, 27518 KiB

Open AccessArticle

Influence of Restraint Conditions on Welding Residual Stresses in H-Type Cracking Test Specimens

by Jiamin Sun, Jonas Hensel, Thomas Nitschke-Pagel and Klaus Dilger

Materials 2019, 12(17), 2700; https://doi.org/10.3390/ma12172700 - 23 Aug 2019

Cited by 17 | Viewed by 3128

Abstract

From the viewpoint of mechanics, weld cracking tends to occur if the induced tensile stress surpasses a certain value for the particular materials and the welding processes. Welding residual stresses (WRS) can be profoundly affected by the restraint conditions of the welded structures. For estimating the tendency of weld cracking, the small-scale H-type slit joints have been widely used for cracking tests. However, it is still hard to decide whether the real large-scale component can also be welded without cracking even though the tested weld cracking specimens on the laboratory scale can be welded without cracking. In this study, the intensity of restraint which quantitatively indicates how much a joint is restrained is used. The influence of restraint condition (intensity of restraint) on WRS is systematically investigated using both the numerical simulation and the experimental method. The achievement obtained in the current work is very beneficial to design effective H-type self-restrained cracking test specimens for evaluating the sensitivity of the material and the welding procedures for weld cracking in the real large-scale components. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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13 pages, 15567 KiB

Open AccessArticle

Optimization on Reducing Slag Entrapment in 150 × 1270 mm Slab Continuous Casting Mold

by Yang Wang, Shufeng Yang, Feng Wang and Jingshe Li

Materials 2019, 12(11), 1774; https://doi.org/10.3390/ma12111774 - 31 May 2019

Cited by 15 | Viewed by 2684

Abstract

To reduce slag entrapment in 150 × 1270 mm slab continuous casting molds at the Tang Steel Company, the effect of submerged entrance nozzle (SEN) depth and casting speed on the phenomenon was studied by computational fluid dynamics simulations. Then, the slag entrapment behavior in continuous casting molds, utilizing Large Eddy Simulation (LES) by coupling the volume of fluid (VOF) method, was also used. Finally, the effect of several common oils usually used to simulate slag in water modelling on slag entrapment was discussed and the water modelling results were used to validate the numerical simulation findings. The results showed that the optimum scheme is a submerged depth of SEN 90 mm and a casting speed of 1.6 m/min. Under optimal conditions, the maximum surface velocity is smallest (0.335 m/s) and the maximum slag entrapment ratio (0.44%) appears in the position of 0.1 m below the meniscus after 15 s. The water modelling results were in good agreement with the numerical simulation results. Full article

(This article belongs to the Special Issue Modeling of Materials Manufacturing Processes)

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